Apparatus for molding, blocking, or otherwise shaping materials, hats, or articles



Aug. 2, 1938. GD. WEIR 2,125,760

APPARATUS FOR MOLDING, BLOCKING, OR OTHERWISE SHAPING MATERIALS, HATS, OR ARTICLES Filed April 9, 1955 2' Sheets-Sheet 1 6. D Wei) Aug. 2, 1 938.

cs. D. WEIR 2,125,760 APPARATUS FOR MOLDING, BLOCKING, OR OTHERWISE SHAPING MATERIALS, HATS, OR ARTICLES Filed April 9, 1935 2 ShetS-Shet 2 Patented Aug. 2, 1938 PATENT oFFicE APPARATUS FOR MOLDING, BLOCKING, OR OTHERWISE SHAPING MATERIALS, HATS,

OR ARTICLES George David Weir, Caulfield, Victoria, Australia Application April 9, 1935, Serial No. 15,469

In Australia 6 Claims.

This invention has reference to improved apparatus for molding, blocking or otherwise shaping materials or substances such as felts, fabrics, velvet, leather goods, straw hats, and has been devised to provide such apparatus that will readily mold or shape the materials specified to the desired shape or contour in a more eificient and expeditious manner than has hitherto been achieved.

The invention has for itsobject the production of apparatus to effect the blocking and shaping of felt or fabric hats or like articles and in which vacuum pressure is used in conjunction with compressed air to effect the co-operation between a fixed molding member, a movable molding or stretching member and a resilient molding member or bag whereby fabric, straw or felt disposed on the fixed molding member is firstly subjected to an initial molding or stretching operation by vacuumpressure drawing the movable member into engagement with the material while the disengagement of the movable member by compressed air permits the resilient molding memberor bag to be broughtinto engagement by vacuum with the partly formed hat and thereby engage with the entire surface thereof to effect the shaping and blocking of the hat.

It is a feature of the invention that during the initial molding or stretching operation by the movable mold above described, stretching mechanism is synchronously actuated to exert an outward pressure on thebrim of the hat or article simultaneously with the crown being stretched into shape whereby the desired complete shape and size of the brim and crown is achieved.

In order that the invention may be more readily understood reference will now be made to the accompanying drawings in which:

Figure 1 is'a side elevation of apparatus constructed in accordance with this invention and as, applied tothe manufacture of hats or like articles, and-- Figure 2 is a plan thereof.

Figure 3 is a section taken on line AA on Figure 2. l

Figure 4 is a plan of the apparatus with the resilient molding member and fixed mold removed. i l

Figure 5 is a detailinsection of the resilient molding member, and- Figure 6 is a plan thereof. Figure 7 is a detail of the brim stretching mechanism.

Figure 8 is a central section of: the fixed mold April 21; 1934 with a hat in position thereon and the resilient molding member in the operative position.

Figure 9 is a diagrammatic view of the pipe circuit for controlling the supply of vacuum and compressed air. 1 According to one form of carrying this invention into practical effect and as illustrated in Figures 1 to 3 of the accompanying drawings, the apparatus may be utilized in one application for the shaping, molding and blocking of felt or straw hats or like articles, the apparatus having as its pressure creating medium the utilization of vacuum independently or in conjunction with compressed air.

The apparatus comprises a cylindrical casing 2 to provide a main vacuum chamber 3 open at V the top and around which is formed a perforated plate or table 4 preferably circular and formed integral with the casing 2. The casing 21 is adapted to seat on a work bench or structure at a height convenient for the workman to operate over the perforated plate or table Mounted in the open top of the vacuum chamber 3 which constitutes a recess in the perforated table 41 is an interchangeable hat mold 5 of the desired configuration according to the predetermined shape of the hator article to be molded and blocked.

The mold 5 is of a recessed or hollow nature with thehollow portion 6 having substantially small perforations I therein or passages to communicate with the interior of the vacuum chamher 3. The flange 1* of the mold 5 isdetachable from the perforated body portion 6 by spaced lugs 8 adapted to receive studs or bolts 8 The flange 1 of the mold 5 is suitably shaped to accord with the shape it is desired to impart to the brim of the hat. The formation of the perforated mold 5 in' two parts permits the production of hats having varied sized crowns and peculiarly shaped brims to accord with the prevailing fashion.

The fiange of the mold 5 is provided at'its periphery with downturned circumferential lugs 9 whereby a space or clearance .EI' is provided between the inside of the flange and the top i of the perforated table 4 for the purpose hereinafter described.

Disposed within the vacuum chamber 3 at the bottom thereof is an electric or other heater III while a steam pipe is connected thereto to maintain the felt or like. material in a heated and soft pliable condition t6 facilitate the ready working and blocking thereof in accordance with standard practice.

A resilient pressure creating molding member or bag 2 is positioned on the upper surface of the perforated plate or table 4 to cover the entire surface thereof. The resilient molding member I2 is supported in a hinged frame l3 mounted on the edge of the perforated table 4, a double hinge formation |4 being provided as illustrated in Figure 2 to facilitate the folding back of the said resilient member clear of the fixed mold 5. The resilient member I2 is preferably composed of a readily elastic and resilient agent or material such as rubber. tudinally or radially through the thickness of the rubber member |2 are a plurality of tubular reinforcements I6 which may be in the form of metallic tubes, or tubes helically wound with wire or like material. As shown in Figure 5 the helically wound reinforcements I6 are porous to per mit the withdrawal of air from the passages lfi accommodating said spaced holes or ducts It formed on the underside of the resilient member I2.

The resilient member |2 is constructed in the manner of a bag whereby, under pressure, sufficient material is available to permit the same being drawn into the recess or hollow 6 of the fixed perforated mold 5. The perforations in the table 4 prevent the formation of air pockets between it and the marginal portion of the resilient member l2 and permit the latter to lie flat upon the table 4.

It will be understood that although the fixed mold 5 is illustrated in this embodiment of the invention as being of a hollow or recessed nature, it could be inverted to assume an upraised position on the perforated table.

The passages I6 with the tubular reinforcements H5 in the resilient member l2 are of particular utility in that a dual purpose is achieved of reinforcing the material and providing passages therein to permit the ready withdrawal of air through the ducts lfi from all parts of the resilient member l2 when same is subjected to the action of vacuum to ensure that the resilient member l2 conforms exactly to the hat or article ll positioned in and on the fixed perforated mold 5 to impart pressure thereto to effect the blocking operation, as will be hereinafter described.

Superimposed above the fixed perforated mold 5 and in direct operative alignment therewith, is a movable mold or stretcher |8 which is adjustably mounted on a crosshead l9 diametrically disposed above the perforated table 4 to be connected at each extremity to the upper end of a piston rod 20. Each piston rod 20 is fitted to a piston 2| mounted in enclosed cylinders 22 vertically positioned and suitably supported in relation to the perforated table 4. The function of each piston 2| is that on the admission of vacuum or suction to the underside of the pistons same are drawn downwardly in their respective cylinders 22 to'bring the movable mold or stretcher l8 into the recess or hollow 6 of the fixed perforated hollow or mold 5. The movable mold or stretcher I8 is the male member and is shaped and of a size to provide a working fit within the fixed mold 5 when a hat or article is positioned therein.

The apparatus is provided with stretching mechanism to.effect a stretching operation on the brim of the hat or article simultaneously with the descent of the movable mold or stretcher l8 as' illustrated in Figures 2 and 3. The stretcher mechanism comprises gripping elements 23 which are adapted to 'operate under vacuum' pressure Formed transversely and longireinforcementsl through.

to draw the brim of the hat I! outwardly simultaneously with the crown being stretched by the mold IS. The gripping elements 23 comprise a plurality of pivoted fingers 24 connected to a flexible and substantially fiat and narrow strap 25, which in each instance is fitted to the upper end of a piston 26. The pistons 26 are mounted in cylinders 21 radially disposed around the perforated plate or table 4. Each inner end of the pivoted fingers 24 has fitted thereto a thumb screw 28 and cleat 29 in order that the adjacent edge of the brim of the hat or article may be gripped and fastened between the pivoted fingers 24. In this manner the periphery of the brim of the hat or article I! is at selected spaced intervals gripped by the pivoted fingers 24 fastened thereto in the manner illustrated, each set of fingers 24 having a common flexible extension 25 to an independent piston 26 the cylinder 21 of which has a port 29 at the base whereby, on

the admission of vacuum to the respective cylinders 21, each piston 26 is drawn downwardly to exert a pull on the flat extensible lead 25 to exert a stretching pressure on the brim of the hat or article.

Each of the cylinders 21 is connected by a common pipe 2'! this pipe being connected by valve 28 to vacuum or compressed air.

A plurality of spaced and inter-related compartments 30 are formed radially around the main casing 2, as illustrated more particularly in Figures 2 and 3 of the drawings. The compartments 30 are disposed below the perforated plate or table 4 and at their inner extremities are provided with passages 3| which extend into a tube 32 which is common to all the compartments 30, the outer ends of which are sealed.

The tube 32 has a pipe 33 connected thereto which extends through a four way valve 34 to a combined vacuum and compressed air pump 35 while the four way valve 34 has a union connecting a pipe 36 which extends through a check valve 31 to the main vacuum chamber 3. The compressed air section of the combined pump 35 has a pipe 38 leading through a check valve 39 and two-way cook 40 to the pipe 4| which extends through check valve 42 to the cylinders 22 for operating the crosshead l9 and movable moldl8. r

The pipe 33 from the compartments 30 to the four-way valve 34 and two-way valve 40 is adapted to admit vacuum or suction to the bottom of one of the cylinders 22 inwhich is operatively disposed the pistons 2| for raising and lowering the crosshead |9 carrying the movable mold or stretcher l8, a supply pipe 43 being connected to the pipe 4| .to by-pass suction or vacuum to the other co-acting cylinder 22 supporting the crosshead |9.

The operation of the apparatus is as follows:-

In accordance with accepted practice a felt or straw hat or like article is firstly shaped on a wooden frame to the approximate shape and size desired; the felt or fabric during this operation is softened with steam or other agents to make it soft and pliable. The partly formed hat or article I1 is then in a condition to be placed on the fixed perforated mold 5; the brim of the hat I! rests on the shaped flange l of the mold 5 while the crown seats inthe hollow or recess 6 of said mold. Prior to placing the hat I"! in po-, sition the four-way valve 34 is adjusted to admit suction to the plurality of storage compartments 30 disposed below the perforated table 4 to evacuate said compartments.

area -mo j -'Afelt liner 45 ispositioned over the hat or article disposed in the fixed mold 5.--The fixed mold is perforated as at I and the porosity of the-felt hat and liner 45 is' such that when vacuum or suction is exerted from themain chamber the resilient molding member I2 is drawn into the recess 6 of the fixedmold 5. a

After the vacuum storage compartments 36 have been evacuated and thepartly formed hat I ahdfelt liner 45 hasbeen disposed in the fixed mold 5, vacuum is admitted to thecylin ders 22 incorporating the pistons 2| to operate afcrosshead l9. s

The admission of vacuum to the said cylinders 22 draws the pistons 2| downwardly and the movable mold or stretcher I8 is drawn intothe felt liner 45 to impart the initial'molding or stretching operation;- i *Ifthe hat or article is composed of strawor like material the lower section 6* of the fixed mold may be dispensed with and then a stretching operation only is imparted to the crown of the hat l! by the movable mold or stretcher l8.

Simultaneously with the operation described vacuum is admitted to the cylinders 21 incorporating the pistons 26 which connect the flat extensible straps 25 of the'pivoted fingers constituting the brim stretching mechanism. All the pistons 26 are synchronously drawn downwardly in their respective cylinders 21 which moves the extensible straps 25 outwardly from .thebrim of the hat or article I! whereby the pivoted fingers 24 impart a stretchingpressure to the brim around the entire periphery thereof. As this action takes place simultaneously with the movable mold or stretcher 'IB imparting the initial molding or stretching operation tothe crown of the hat or article, the same is therefore stretched and partly formed to the predetermined shape.

After. the crown of the hat has been subjected to the stretching operation by adjusting the fourway valve 34 and check valve 28, compressed air is admitted to the underside of the cylinders 22 which incorporate the pistons 2| carrying the crosshead l9 whereby said pistons 2| are forced upwardly in their respective cylinders 22 to elevate the crosshead l9 which withdraws the movable mold or stretcher I8 to its upper inoperative position. By closing the check valve 42 the crosshead 19 will remain in the upper position for a period sufficient at least to permit the completion of the molding and blocking of the hat or article. The stretching mechanism is retained in the operative position, that is, the cylinders 21 in which the respective pistons 26 are mounted to actuate said mechanism are retained under vacuum. The resilient molding member is then adjusted by its double hinge formation to cover the entire surface of the perforated table 4.

In accordance with the pipe circuit illustrated in Figure 9, the fourway valve 34 is then adjusted to connect the vacuum storage compartments 30 with the main vacuum chamber 3. The resilient molding member I2 is, when valves 31 and fourway valve 34 are operated subjected over its entire effective area to the influence of Vacuum, that is, all the air in the resilient member 12 is withdrawn owing to the differential of air pressures between the main vacuum compartment 3 and the storage compartments 30 whereby the main vacuum chamber 3 is evacuated and air is withdrawn from the inside of the resilient member l2 to cause the same to extend into and conformvto the shape of the partly formed hatll-l in the fixed mold 5. 1

The fourway valve'34 is then again adjusted to disconnect the compartments 34 withthe main chamber 3 andconnect the same with the vacuum pump 35 whereby continuous suction is exerted on the main chamber 3. Suction is therefore exerted through the perforated mold 5, hat or article I! and felt liner 45, on to the surface of the resilient member l2 engaging with and in conformity with the partly formed hat or article.

The continued pumping operation exerts pressure' on the resilient member l2 and draws it forcibly against the inside of the felt liner 45 and-the surface of the flange thereof whereby the hat or article within the liner is blocked to the predetermined shape. The substantially flat and narrow formation of the extensible members 25 attached to the gripping elements 24 does not affect the positive closure of the resilient molding member l2 under the influence of the vacuum exerted from the main chamber.

After the blocking operation described has been "effected, the fourway valve 34 is closed and compressed air is passed through the twoway valve 4|] through check valve 28 into the distributing pipe21 'to each of the cylinders 21 which have the pistons 26 therein to actuate the stretching mechanism. The tension is released in the gripping elements 23 by the pistons 26 in the cylinders 21 rising under the action of the compressed air and therefore the same may be detached from the brim of the hat after the vacuum has been broken in the main chamber.

I By breaking the vacuum in the main chamber on the admission of atmosphere or compressed air through the pipe system described, the resilient molding member l2 may be folded back from its double hinge clear of the perforated mold 5 to permit the removal of the blocked hat or article from said mold.

As the pistons 2| which carry a crosshead l9 and support the gripping elements respectively are raised to the inoperative position by the admission of compressed air below said pistons 2| the latter will drop after the compressed air 1113.513881]. out 01f and, therefore, before the apparatus canbe used to block or mold a new hat or article compressed air would have to be again admitted to the underside of said pistons to raise the crosshead 19 to its normal position and cause the gripping elements to assume a position for attachment respectively.

What I claim as my invention and desire to secure by Letters Patent is:--

1. Apparatus for molding, blocking or otherwise shaping materials comprising a casing having a vacuum chamber therein, a perforated fixed mold on said casing to receive a hat or article to be shaped or molded, a movable mold adapted under the action of vacuum and compressed air to engage and disengage respectively with said fixed mold, means to stretch the brim of said hat outwardly synchronously with the movable mold engaging with the fixed mold and a resil ient pressure creating and molding member mounted on said casing to close on to and grip the hat or article on said fixed mold after the movable mold has been displaced from engagement therewith.

2. Apparatus for molding, blocking or otherwisev and over the vacuum chamber to receive a'partly formed hat or article, a movable mold operatively disposed above the fixed mold and adapted under the action of vacuum and compressed air to engage and disengage respectively with the fixed mold, stretching mechanism on the perforated table to grip and stretch the brim of said hat or article synchronously with the movement and engagement of the movable mold with the fixed mold, and a resilient pressure creating and molding member hingedly mounted on said table and adapted under the action of vacuum to grip and forcibly conform to the shape of the hat or article on the fixed mold to effect the blocking thereof after the movable mold has been returned to the v inoperative position.

3. In apparatus for molding, blocking or otherwise shapingmaterials, a fixed perforated mold to receive a partly formed hat or article, a mov-' able mold adapted to engage and disengage respectively with said fixed mold, stretching mechanism to grip and stretch a brim on the hat or article, a resilient molding member to exert pressure on the hat or article, the movable mold, stretching mechanism and resilient molding member being operated to shape the hat or article under the action of vacuum, the said movable mold and stretching mechanism being returnable to a normal position by the action of compressed air.

4. Apparatus for molding, blocking or otherwise shaping materials, comprising a casing having a vacuum chamber therein, a perforated tablemounted on said casing, a fixed perforated mold-disposed on and over said casing, a plurality of vacuum storage compartments arranged below and in valve controlled communication with said vacuum chamberwhereby vacuum may be imparted from said compartments to said chamber to withdraw air through the perforated mold, and an imperforate resilient pressure-creating and molding member disposed on the perforated table adapted, when air is withdrawn through the perforated mold, to conform to and forcibly engage with a material, substance, hat or article disposed on said perforated mold for the purposes herein specified.

5. In apparatus for molding, blocking or otherwise shaping materials comprising a casing having a vacuum chamber therein, a perforated fixed mold on said casing to receive the material, substance, hat or article to be shaped or molded, a movable mold adapted under the action of vacuum and compressed air to engage and disengage respectively with the fixed mold, and an imperforate resilient pressure-creating and moldingrnember adapted under the action of vacuum to close on to, grip and conform to the shape of the material, substance, hat or article on said fixed mold after the movable mold has been displaced from engagement therewith, perforate tubular reinforcements disposed within the resilient pressure creating and molding member to form internal passages therein and spaced ducts formed in the underside of said member to communicate with said passages.

6. Apparatus for blocking or otherwise shaping materials, comprising a casing having a vacuum chamber therein, a perforated table on said casing, a fixed mold detachably mounted in the top of the vacuum chamber with the flange of said mold seating in spaced relationship on the perforated table, said mold being perforated and hollow to receive the crown of a partly formed hat or article with the brim thereof impinging on the flange, a movable mold operatively disposed above the fixed mold, a crosshead on which the movable mold is mounted, vacuum operated means connected with the crosshead to lower the movable mold into the fixed mold, said movable mold being returnable to the inoperative position under the action of compressed air, a plurality of gripping elements to engage at selected positions with the brim of the hat or article to stretch the same outwardly during the descent and operation of the movable mold, said stretching mechanism being returnable to the inoperative position under the action of compressed air, and a resilient pressure-creating and molding member hingedly mounted on the perforated table adapted under the action of vacuum to close on to and forcibly engage with the hat or article after the movable mold has been returned to the inoperative position.

GEORGE DAVID WEIR. 

